EN
Service Manual
PumpMaple 15/6
104205• Model
77-3244 R1.1 1/20 www.carlisleft.com
EN
D Smith
Director of Sales (EMEA)
13/4/17
Bournemouth,BH11 9LH,UK
EU Declaration of Conformity
The object of the declaration described above is in conformity with the relevant Union
harmonisation legislation:
Machinery Directive 2006/42/EC
ATEX Directive 2014/34/EU
by complying with the following statutory documents and harmonized standards:
EN ISO 12100:2010 Safety of Machinery - General Principles for Design
EN 12621:+A1:2010 Machinery for the supply and circulation of coating materials under pressure - Safety
requirements
EN 1127-1:2011 Explosive atmospheres - Explosion prevention - Basic concepts
EN 13463-1:2009 Non electrical equipment for use in potentially explosive atmospheres - Basic methods and
requirements
EN 13463-5:2011 Non electrical equipment for use in potentially explosive atmospheres - Protection by
constructional safety "c"
Providing all conditions of safe use / installation stated within the product manuals have been
complied with and also installed in accordance with any applicable local codes of practice.
Si
g
ned for and on behalf of Carlisle Fluid
Technologies UK Ltd:
Product Description / Object of Declaration: Pumps - Maple, DVP, 104009, 104010/LS, 104016,
104027, 104032, 104040/1/2, 104077, 104020,
104023, 104025, 104028/9, 106933, 104205,104149-
52, 104207-15.
This Product is designed for use with: Solvent and Water based materials
Suitable for use in hazardous area: Zone 1
Protection Level: II 2 G X IIB T4
Notified body details and role: Element Materials Technology (0891)
Lodging of Technical file
This Declaration of conformity / incorporation
is issued under the sole responsibility of the
manufacturer:
Carlisle Fluid Technologies UK Ltd,
Ringwood Road,
Bournemouth, BH11 9LH. UK
77-3244 R1.1 2/20 www.carlisleft.com
EN
In this part sheet, the words WARNING, CAUTION and NOTE are used to emphasize important safety information as
follows:
WARNING CAUTION
READ THE MANUAL. Before operating finishing equipment, read and
understand all safety, operation and maintenance information
provided in the operation manual.
AUTOMATIC EQUIPMENT. Automatic
equipment may start suddenly without
warning.
WEAR SAFETY GLASSES. Failure to wear safety glasses with side
shields could result in serious eye injury or blindness. PROJECTILE HAZARD. You may be
injured by venting liquids or gases that
are released under pressure, or flying
debris.
DE-ENERGIZE, DE-PRESSURISE, DISCONNECT AND LOCK OUT ALL
POWER SOURCES DURING MAINTENANCE. Failure to de-energize,
disconnect and lock out all power supplies before performing
equipment maintenance could cause serious injury or death. KNOW WHERE AND HOW TO SHUT
OFF THE EQUIPMENT IN CASE OF AN
EMERGENCY.
NOISE LEVELS. The A-weighted sound level of pumping and spray
equipment may exceed 85 dB(A) depending on equipment settings.
Actual noise levels are available on request. It is recommended that
ear protection is worn at all times while equipment is in use.
PRESSURE RELIEF PROCEDURE.
Always follow the pressure relief
procedure in the equipment instruction
manual.
INSPECT THE EQUIPMENT DAILY. Inspect the equipment for worn or
broken parts on a daily basis. Do not operate the equipment if you
are uncertain about its condition.
OPERATOR TRAINING. All personnel
must be trained before operating
finishing equipment.
EQUIPMENT MISUSE HAZARD. Equipment misuse can cause the
equipment to rupture, malfunction or start unexpectedly and result in
serious injury. PACEMAKER WARNING. You are in the
presence of magnetic fields which may
interfere with the operation of certain
pacemakers.
HIGH PRESSURE CONSIDERATION. High pressure can cause serious
injury. Relieve all pressure before servicing. Spray from the gun,
hose leaks or ruptured components can inject fluid into your body
and cause extremely serious injury. KEEP EQUIPMENT GUARDS IN PLACE.
Do not operate the equipment if the
safety devices have been removed.
STATIC CHARGE. Fluid may develop a static charge that must be
dissipated through proper grounding of the equipment, objects to be
sprayed and alll other electrically conductive objects in the dispensing
area. Improper
g
roundin
g
or sparks can cause a hazardous condition
and result in fire, explosion or elecrtic shock and other serious injury.
PROP 65 WARNING. WARNING:This product contains chemicals
known to the state of California to cause cancer and birth defects or
other reproductive harm.
PINCH POINT HAZARD. Moving parts
can crush and cut. Pinch points are
any areas where ther are moving
parts.
IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PROVIDE THIS INFORMATION TO THE
OPERATOR OF THE EQUIPMENT.
NOTE
Hazards or unsafe practices which could result in
severe personal injury, death or substantial property
damage.
Hazards or unsafe practices which could result in
minor personal injury, product or property
damage
Important installation, operation or maintenance
information.
WARNING
Read the following warnings before using this equipment.
NEVER MODIFY THE EQUIPMENT. Do
not modify the equipment unless the
manufacturer provides written
approval.
77-3244 R1.1 3/20 www.carlisleft.com
Sanitary
Sanitary1"
1"
283 l/m [10 CFM]
A
ir consumption @ 30 cycles/min and 6 bar [87 psi] air inlet
pressure: 566 l/m [20CFM]
EN
Specification
Ratio: 6:1
Maximum air inlet pressure: 7 bar [101.5 psi]
Maximum fluid pressure: 42 bar [610 psi]
Nominal flow volume / cycle: 0.375 l/m [0.10 US gal/m]
Output @ 60 cycles / min: 22.5 l/m [6 US gal/m]
Dirt: 5 microns
Water: -20°C @ 7bar [940ppm]
Maximum recommended continous cycle rate:
Cycles/min 20
Maximum recommended intermittent cycle rate:Cycles/min 40
Fluid inlet connection:
Fluid outlet connection:
Compressed Air Inlet 3/8" BSPP / NPSM
A
ir consumption @ 15 cycles/min and 6 bar [87 psi] air inlet
pressure:
Max. Pump Fluid Inlet Pressure 2 bar [30 psi]
A
ir Quality ISO 8573.1 Class 3.3.2
Air volume / cycle @ 3.1 bar/45psi:
Air volume / cycle @ 6.2 bar/90psi:
9.5 l/m [0.33 SCFM]
18.5 l/m [0.65 SCFM]
# See Note Oil: 0.1mg/m³
Weight: 45.5 kg / 91 lbs
# Note: Class 3.4.2 Air Quality (Refrigerant dried - water +3ºC@7bar) may be used, however,
above 15 cycles/min optional heavy duty mufflers 192821 or piped exhaust system should
be used, if used continuously.
77-3244 R1.1 4/20 www.carlisleft.com
EN
Dimensions and Mounting Details
MOUNTING LOCATIONS
SECTION A-A
1" Sanitary outlet
1" Sanitary inlet
EARTHING POINT
AIR INLET
77-3244 R1.1 5/20 www.carlisleft.com
EN
Installation
This product should be flushed with a suitable compatible solvent prior to use.
Mount the pump securely and position the pump at a convenient height (below the lid height of the
paint container), to allow for maintenance, visual observation, and periodic inspection.
The wall mount bracket is included with all pumps.
The Pump Mounting bracket must be connected to a suitable earth ground to ensure that there is no
possibility of static build up.
Attach suitable flexible hoses to the inlet and outlet connections.
Connect a suitable 3/8" NB air hose and 1/2” Pressure Filter Regulator to the air motor.
(Filter rated at minimum 1000 l/min)
No additional air lubrication is required as piston ring lubricant is applied during assembly or repair.
If an air lubricator is used then this must be maintained.
77-3244 R1.1 6/20 www.carlisleft.com
EN
Installation
Set the pump speed to a slow cycle rate and prime the pump to remove any air before increasing
pressure.
Inspect for any air or fluid leaks.
Set the pump cycle rate to achieve the required paint volume and then adjust the system back
pressure regulator and pump air pressure to achieve the desired system fluid pressure.
A Back Pressure Regulator should be mounted in the paint system return line.
The return line ‘back pressure’ regulator responds to the changes in system fluid flow demand, (due to
variable paint usage) by dynamically adjusting the paint flow rate returning to the system paint tank,
thus maintaining the set pressure.
If an air blow out system is used, never exceed 2 bar [29 psi] on the inlet of the pump.
Exhaust kits are available for these pumps if the air exhaust is required to be piped away from the
pump rather than exhausting locally through the mufflers.
77-3244 R1.1 7/20 www.carlisleft.com
EN
2
M12 16
M8 8
1" 2
1/4" 4
1" 2
1
2
1
1
1
2
Ø70 2
1
2
2
2
2
3
SILENCER
LABEL
SEAT
OUTLET MANIFOLD
INLET MANIFOLD
165108
177107
177109
177111
192206
192382
192505
192551
192712
192777
192816
192833
192835
193360
SANITARY GASKET
BALL
Ø12.42 x 1.78 O-RING
HEXAGON PLUG
Ø37.82 x 1.78 O-RING
LABEL
OUTLET FITTING
PISTON ASSEMBLY
1 & 1 1/2 SANITARY CLAMP
AIR MOTOR ASSEMBLY
OUTLET CYLINDER
M12 x 50
SPRING WASHER
SPRING WASHER
SOCKET HEAD CAP SCREW
M8 x 65 SOCKET HEAD CAP SCREW
M12 X 110 SOCKET HEAD CAP SCREW
20 4
19
13
14
15
24
194179
194242
194845
194971
194974
194976
194979
41-4404
193775
#
21
22
23 PISTON SEAL
INLET CYLINDER
BALL CAGE25
Parts list - Pump Assembly
ITEM QTY REMARKS
2
1
PART NO. DESCRIPTION
RIVET164838 Ø2 x 4.75
165044
17
18
71"
4
4
5
68
8
16
8
10
12
8
94
11 6
77-3244 R1.1 8/20 www.carlisleft.com
EN
Pump Assembly
KEY
= LOCTITE
= TORQUE
= MAINTENANCE ORDER
(Reverse for assembly)
= GREASE INTERNAL
(AGMD-010)
= GREASE
(AGMD-010)
77-3244 R1.1 9/20 www.carlisleft.com
EN
2
1
2
2
M8 16
M8 16
M4 4
M4 4
2
2
1
6
2
2
2
2
1
2
1
CYLINDER STUD - LONG192762
4
DOME NUT
PLAIN WASHER
SPRING WASHER
163920 4M6 x 30 SOCKET HEAD CAP SCREW
11 165528 M4 x 16 SOCKET HEAD CAP SCREW
RETAINING NUT
KNIFED BELLOWS
15
20
165108
12 165963
10
16199232
Ø117.5 x 2.62 O-RING
O-RING
O-RING
Parts list - Air Motor Assembly
ITEM PART NO. QTY REMARKS
10115-010037 POPPET ASSEMBLY
#
20115-010102 AIR VALVE ASSEMBLY
7162703 SHAFT SEAL
4
177038 M10 x 12 BUTTON HEAD CAP SCREW 4
161993
5161994
AIR CYLINDER
25 192814
DESCRIPTION
192761 CYLINDER STUD
24 192812 EXHAUST ADAPTER
16597013
8162704 SHAFT BEARING
16 192374
2
16597114
6161995 O-RING 2
Ø19.5 x 3
SPRING WASHER
9
4
Ø20.35 x 1.78
Ø4.47 x 1.78
19257917
#
21 192763 BELLOWS SPACER
22 192764 PUMP BRACKET
23 192799 VENT PLUG
18 192757
19
1
BELLOWS LEAK
DETECTION HOSE
AIR MOTOR PISTON
28 194972 END PLATE MACHINING 2
PUSH IN ELBOW19281526
27 194293
77-3244 R1.1 10/20 www.carlisleft.com
EN
ITEM 7
DETAIL
KEY
= LOCTITE
= TORQUE
= MAINTENANCE ORDER
(Reverse for assembly)
= GREASE INTERNAL
(AGMD-010)
= GREASE
(AGMD-010)
77-3244 R1.1 11/20 www.carlisleft.com
EN
2
1
3192759 PISTON SHAFT
4192760 PISTON
Air Motor Piston Assembly
ITEM PART NO. DESCRIPTION QTY REMARKS
GRUB SCREW 1165964 M12 x 402
AIR MOTOR PISTON SEAL 1
1627021
KEY
= LOCTITE
= TORQUE
= MAINTENANCE ORDER
(Reverse for assembly)
= GREASE INTERNAL
(AGMD-010)
= GREASE
(AGMD-010)
77-3244 R1.1 12/20 www.carlisleft.com
EN
1
2
2
2
2
2
2
1
1
1
3/8"
1
10115-010015
Air Valve Assembly
ITEM PART NO. DESCRIPTION
SPOOL AND SLEEVE O-RING
162789 6
Not Shown
QTY REMARKS
50115-010020
DIAPHRAGM
60115-010021
Ø36 x 1.5 O-RING
70115-010049
Ø20 x 2 O-RING
SPOOL AND SLEEVE ASSEMBLY #
20115-010016
BUMPER
30115-010017
MAGNET
40115-010018
VALVE BLOCK END CAP
80115-010073
M4 x 12 BUTTON HEAD CAP SCREW
8
90115-010097
VALVE BLOCK.
10 0115-010103
1/4 BSPT PIPE PLUG
11 0115-010107
1/8 BSPT PIPE PLUG
12 180584
UNIVERSAL FITTING
2
QUICK EXHAUST VALVE CAGE
19281313
= MAGNET HAZARD
KEY
= LOCTITE
= TORQUE
= MAINTENANCE ORDER
(Reverse for assembly)
= GREASE INTERNAL
(AGMD-010)
= GREASE
(AGMD-010)
77-3244 R1.1 13/20 www.carlisleft.com
EN
1
1
Ø56.82 x 2.62 1
1.375 1
1
1
Ø70 1
1
Fluid Piston Assembly
ITEM PART NO. DESCRIPTION QTY REMARKS
2162855
PISTON BALL CHECK SPRING
1605331
1
Ø52.07 x 2.62 O-RING
3162856
4162857
5171788
BALL
6192632
SEAT
Ø41.0 x 1.78 O-RING
O-RING
7193188
INLET SPRING KEEP
8194111
FLUID PISTON
9194113
BALL CAGE
Use a 25mm Single Hex
Socket when tightening or
removing ball cage
from Piston.
KEY
= LOCTITE
= TORQUE
= MAINTENANCE ORDER
(Reverse for assembly)
= GREASE INTERNAL
(AGMD-010)
= GREASE
(AGMD-010)
77-3244 R1.1 14/20 www.carlisleft.com
EN
Fault Finding
Symptom Possible Cause Remedy
Pump will not ‘Prime’
Air getting into the suction hose/manifold Check seals and hose connections.
Worn piston seal. Replace piston seals.
Ball checks not seating correctly. Inspect, clean and/or replace balls
and seats.
Pump will not run
No Air or Fluid supply Check air and fluid supply ball valves
and supply hoses.
Air piston seal worn. Replace piston seal.
Pilot valve assemblies inoperable.
Switch/interchange pilot valves to
isolate faulty pilot valve and
clean/replace.
Pilot valve assemblies inoperable. Check clean/replace Air valve.
QE diaphragm defective.
Check for constant exhaust air when
pump is not running. Check/replace
QE diaphragms.
Ball checks not seating correctly. Inspect, clean and/or replace balls
and seats.
Pump runs but has
excessive pulsation.
Air getting into fluid line, air supply restricted. Check seals and hose connections.
Check air supply
Obstructed fluid ball checks.
Remove, clean, and inspect seat,
ball, and ball cage. Replace if
suspect or worn.
77-3244 R1.1 15/20 www.carlisleft.com
EN
Fault Finding
Symptom Possible Cause Remedy
Pump runs but has
excessive pulsation.
Worn air motor piston seals. Replace air motor piston seal.
Worn/failed air motor shaft seals. Disassemble pump as required to
replace air motor shaft seals.
Worn fluid piston seal. Replace fluid piston seal.
Air exhaust restricted. Check QE diaphragms and exhaust
outlets.
Paint leaking into
detection hose, Air
bleeding from vent
plug
Bellows seal failure Replace bellows seal
Air motor shaft seal leaking Check air motor shaft seal replace as
necessary
77-3244 R1.1 16/20 www.carlisleft.com
EN
1
1
1
1
1
1
1
# -
**
Recommended spare parts for continually running pumps
Note:
Fluid section seal & fluid section overhaul kits contain all the necessary components to service Mark one and two
pistons.
Discard components not required.
Spares Kits for Maple 15/6 Pump
250771 Fluid section seal kit
Check main parts list for
details of individual kit
contents
250772 Fluid overhaul kit
250618 Air Motor Seal Kit
250628 Control Valve Kit
KIT No. PART NO. DESCRIPTION QTY REMARKS
#0115-010037 Poppet Assembly 2 off per pump
#0115-010015 Main Spool & Sleeve Valve Assembly 11 off per pump
#194976 Piston seal 2 off per pump
#192579 Knifed Bellows 2 off per pump
Maintenance schedule
Inspection Operation
Daily Check for any general fluid or air leakage.
Weekly
Inspect Pump for Correct operation
Check for any excessive mechanical noise
Check for excessive fluid pressure pulsation
Perform a pump stall test to ensure correct operation.
If pump does not stall check fluid piston seals and ball checks, replace as required.
12 to 36 Months (Typically 10
million pump cycles
dependant on air quality and
abrasiveness of the paint
used)
Replace air piston seal,
Replace shaft seals & bearings.
Inspect and replace if required: Pilot Air Valves & Main Air Valve Parts.
Replace fluid piston seal,
Replace Balls,Seats and Bellows.
If air is escaping through exhaust check air motor piston seal and quick exhaust
diaphragm, replace as required.
6 Month Test
77-3244 R1.1 17/20 www.carlisleft.com
EN
1
Bellows Replacement
ITEM PART NO. DESCRIPTION QTY REMARKS
502382 Bellows assembly spigot
1
2
1502769 Bellows positioning tool
Screw Item No. 2 (assembly spi
g
ot) onto the
piston shaft
Using Item No. 1, push bellows over spigot
until located in groove.
Smear loctite 572 over nose of bellows,
thread nut onto bellows ensuring the thread
starts squarely. Grip bellows lightly by hand
and tighten the nut with a 1" A/F spanner
until the nut contacts the bellows shoulder.
12
77-3244 R1.1 18/20 www.carlisleft.com
EN
192820 For piped exhaust
Seal Insertion Tool
ITEM PART NO. QTY
192206
192779
3/4" NPT (f) Adapter
Sanitary -
Accessories
1" Sanitary Gasket
194845 1 & 1 1/2" Heavy duty
Sanitary Clamp
194281 1" Sanitary -
1" NPT
(
f
)
Adapter
502608 For Shaft seal (7)
502769 Bellows Positioning Tool
AGMD-010 Kluber Isoflex Topas NB 52 Grease 50ml Tube
502382
Exhaust Tube Adapter (1.25” NB hose)
Bellows assembly spigot
Exhaust Tube Adapter (1” NB hose) For piped exhaust
193275 1"
192803 1" Manifold Plug For piped exhaust
192821 1" BSP Heavy Duty Mufflers Recommended for high pump pressures
and cycle rates
77-3244 R1.1 19/20 www.carlisleft.com
EN
France
Brazil
Germany
www.carlisleft.eu
Tel: +44 (0)1202 571 111
Fax: +44 (0)1202 573 488
WARRANTY POLICY
Binks products are covered by Carlisle Fluid Technologies five year materials and workmanship
limited warranty. The use of any parts or accessories, from a source other than Carlisle Fluid
Technologies, will void all warranties. For specific warranty information please contact the
closest Carlisle Fluid Technologies location listed below.
Carlisle Fluid Technologies reserves the right to modify equipment specifications without prior notice.
DeVilbiss®, Ransburg®, MS®, BGK® and Binks® are registered trademarks of Carlisle Fluid
Technologies, Inc.
© 2018 Carlisle Fluid Technologies, Inc.
All rights reserved.
Binks is part of Carlisle Fluid Technologies, a global leader in innovative finishing technologies. For
technical assistance or to locate an authorized distributer, contact one of our international sales and
customer support locations below.
USA/Canada Mexico
www.carlisleft.eu
Tel: +33(0)475 75 27 00
Fax: +33(0)475 75 27 59
www.carlisleft.eu
Tel: +49 (0) 6074 403 1
Fax: +49 (0) 6074 403 281
China Japan Australia
www.carlisleft.com.cn
Tel: +8621-3373 0108
Fax: +8621-3373 0308
www.ransburg.co.jp
Tel: 081 45 785 6421
Fax: 081 45 785 6517
www.carlisleft.com.au
Tel: +61 (0) 2 8525 7555
Fax: +61 (0) 2 8525 7575
www.binks.com
Toll Free Tel: 1-888-992-4657
Toll Free Fax: 1-888-246-5732
www.carlisleft.com.mx
Tel: 011 52 55 5321 2300
Fax: 011 52 55 5310 4790
www.devilbiss.com.br
Tel: +55 11 5641 2776
Fax: +55 11 5641 1256
United Kingdom
77-3244 R1.1 20/20 www.carlisleft.com
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Carlisle Maple 15/6 Pump Owner's manual
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